Modular welding system

ABSTRACT

A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to, and is a continuation of,co-pending U.S. Non-Provisional application Ser. No. 16/031,733,entitled “MODULAR WELDING SYSTEM,” filed Jul. 10, 2018, which is acontinuation of U.S. Non-Provisional application Ser. No. 13/841,872,entitled “MODULAR WELDING SYSTEM,” filed Mar. 15, 2013, which claimspriority from and the benefit of U.S. Provisional Application Ser. No.61/698,068, entitled “MODULAR WELDING SYSTEM,” filed Sep. 7, 2012, allof which are hereby incorporated by reference in their entirety for allpurposes.

BACKGROUND

The present invention relates generally to the field of welding systems,and more particularly to a modular welding system that can be packagedas a complete system or a partial system.

Welding systems generally have a power supply that applies electricalcurrent to an electrode so as to pass an arc between the electrode and awork piece, thereby heating the electrode and work piece to create aweld. In many systems, the electrode consists of a wire that is advancedthrough a welding torch by a wire feeder. Various components of acomplete welding system may supply the wire, apply the electricalcurrent, and cool the system. However, a complete welding system doesnot provide any flexibility to a purchaser to purchase just the desiredcomponents. Additionally, individual components may be inconvenient totransport.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimedinvention are summarized below. These embodiments are not intended tolimit the scope of the claimed invention, but rather these embodimentsare intended only to provide a brief summary of possible forms of theinvention. Indeed, the invention may encompass a variety of forms thatmay be similar to or different from the embodiments set forth below.

In one embodiment, a welding system includes power conversion circuitryconfigured to convert input power to weld power and a first housingsurface. The first housing surface includes a first mating geometryconfigured to mate with a first complementary geometry of a firstmodular surface of a first modular component of the welding system.

In another embodiment, a welding system includes a wire feeder having awire drive configured to supply a welding wire to a torch and a wirefeeder housing disposed about the wire drive. The wire feeder housingincludes a mating geometry configured to mate with a complementarygeometry of a modular component of the welding system. The modularcomponent includes a swivel, a welding power supply, a torch cooler, ora transportation device, or any combination thereof.

In another embodiment, a method includes interfacing a first housingsurface of a first modular component with a second housing surface of afirst power supply. The first modular component includes a wire feeder,a swivel, or a cooler. The first housing surface includes a first matinggeometry and the second housing surface includes a first complementarygeometry configured to mate with the first mating geometry. The methodalso includes coupling the first modular component to the first powersupply via a first mating relationship between the first mating geometryand the first complementary geometry.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is an assembly view of an embodiment of the modular weldingsystem;

FIG. 2 is a top view of an embodiment of a power supply and a wirefeeder of the modular welding system of FIG. 1 ;

FIG. 3 is a perspective view of an embodiment of a bottom housing of thewire feeder of FIG. 2 having a first mating geometry;

FIG. 4 is a perspective view of an embodiment of the power supply ofFIG. 2 with a top surface having a first complementary geometry to matewith the first mating geometry shown in FIG. 3 ;

FIG. 5 is a perspective view of an embodiment of the modular weldingsystem and one or more mating features between components of the modularwelding system;

FIG. 6 is a perspective view of an embodiment of the modular weldingsystem and one or more mating features between components of the modularwelding system;

FIG. 7 is a perspective view of an embodiment of the modular weldingsystem and one or more mating features between components of the modularwelding system; and

FIG. 8 is a flow chart of a method for assembling the modular weldingsystem.

DETAILED DESCRIPTION

One or more specific embodiments of the present invention will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

The presently disclosed modular welding system embodiments may includeone or more modular components with housings having mating geometriesthat interface with complementary mating geometries on the housings ofopposing modular components. The modular welding system may include, butis not limited to, a wire feeder (e.g., single-wire, dual-wire), a powersupply (e.g., primary switching or inverter power supply,transformer-based power supply), a torch cooler, or a transportationdevice (e.g., cart), or any combination thereof. The components of themodular welding system may be removably coupled to one another via themating geometries. Coupling the modular component may limit the relativemovement between the modular components. Some of the mating geometriesmay include, but are not limited to interlocking (e.g., nesting) housinggeometries, mounting hardware on the housings, shared fastener locationsrelative to a surface of the housings, and the like. For example, someembodiments of modular components (e.g., power supplies) may havehousings with slots, grooves, holes, or recessed portions to receiveextension portions (e.g., flanges, posts, hooks) of an interfacingmodular component (e.g., wire feeder). Some embodiments of the modularwelding system may have housings with shared patterns of mating featurelocations among the components, thereby reducing the complexity ofremovably coupling the modular component to one another. In someembodiments, the mating geometries may passively and/or removably couplemodular components without utilizing tools (e.g., screw driver, wrench,etc.).

In some embodiments, the modular components may be rotatably coupled toone another, thereby limiting relative translation motion and permittingsome relative rotational motion, such as between the wire feeder and thepower supply. Removably coupling the modular components to one anotherenables the operator to configure the modular welding system for aparticular welding application utilizing only the selected modularcomponents. The modular components may be coupled so that the modularwelding system has flush surfaces (e.g., vertical surfaces such as thefront, sides, rear surfaces) between the modular components, which mayreduce snags and/or reduce a dimension (e.g., width, length) of themodular welding system. In some embodiments, the modular components maybe removably coupled in a vertical stack, thereby reducing a footprintof the welding system.

Turning to the figures, FIG. 1 is an assembly view of an embodiment of amodular welding system 10 showing multiple modular components that maybe coupled together. The modular components may include, but are notlimited to, a wire feeder 12 (e.g., single-wire wire feeder 14, adual-wire wire feeder 16), a swivel 18, a power supply 20 (e.g., a firstinverter power supply 22, a second inverter power supply 24, atransformer power supply 26, a torch cooler 28, and a transportationdevice 30. As may be appreciated, the wire feeder 12 may have a spool ofwelding wire (e.g., electrode) and a wire drive to supply the weldingwire to a torch for a welding application (e.g., metal inert gas (MIG)welding). In some embodiments, the welding wire may be a solid, hollow,or flux-cored welding wire. The power supply 20 has power conversioncircuitry that receives input power from a power source, and convertsthe input power to weld power suitable for the welding application. Thewire feeder 12 and the power supply 20 may be communicatively coupled bysignal cables and/or weld cables. In some embodiments, the power supply20 supplies weld power to the wire feeder 12 to perform the weldingapplication.

The dashed lines 32 of FIG. 1 illustrate an embodiment of aconfiguration for coupling the modular components together in themodular welding system 10. As discussed below, some modular components(e.g., swivel 18, torch cooler 28, transportation device 30) may beomitted from some embodiments of the modular welding system 10.Additionally, some embodiments may couple one wire feeder 12 (e.g.,single-wire wire feeder 14) and/or one power supply 20 (e.g., firstinverter power supply 22) in a modular welding system, and leave anyadditionally wire feeders 12 (e.g., dual-wire wire feeder 16) and/orpower supplies 20 (e.g., second inverter power supply 24) to beavailable for use in other welding systems (e.g., another modularwelding system 10). Additional modular components may be utilized asreplacement modular components that are switched with active modularcomponents for maintenance. Accordingly, the modular components may beremovably coupled in various combinations based at least in part on anoperator's desired welding application. For example, the operator maynot utilize a wire feeder 12 for a stick welding application or atungsten inert gas (TIG) welding application, or the operator may electto forgo the torch cooler 28 for a relatively short duration weldingapplication.

A wire feeder bottom housing 34 may be removably coupled to a firsthousing surface 36 of the swivel 16 or to a second housing surface 38 ofa power supply 20. The wire feeder bottom housing 34 has a first matinggeometry, and both the first and second housing surfaces 36, 38 have afirst complementary geometry that couples with the first matinggeometry. In some embodiments, the wire feeder bottom housing 34 and thefirst or second housing surfaces 36, 38 share a first hole pattern 40(e.g., bolt holes) to accommodate fasteners. A lift eye 42 or otherstructure may extend from the second housing surface 38 of the powersupply 20 along a vertical axis (e.g., Y-axis 44) to mate with a recess46 of the swivel 18 and/or the wire feeder 12. The lift eye 42 mayfacilitate positioning the wire feeder 12 and/or the swivel 18 relativeto the power supply 20. For example, faces of the wire feeder 12 and/orthe swivel 18 may be aligned with or spaced apart (e.g., set back) fromfaces of the power supply 20 utilizing the lift eye 42. In someembodiments, the power supply 20 may removably couple with the swivel 18and/or the wire feeder 12 along a horizontal axis (e.g., X-axis 48,Z-axis 50) via a channel and mating flange as discussed in detail below.Moreover, the wire feeder bottom housing 34 may interlock (e.g., nest)with the first housing surface 36 and second housing surface 38. Thewire feeder bottom housing 34 may be removably coupled to the firsthousing surface 36 and/or second housing surface 38, thereby limitingmovement of the wire feeder 12 along the coordinate axes 44, 48, 50relative to the power supply 20.

The swivel 18 may enable the wire feeder 12 to rotate relative to powersupply 20. For example, the swivel 18 enables the wire feeder 12 torotate about the vertical axis 44 as shown by arrow 52. Rotation of thewire feeder 12 via the swivel 18 to direct the wire from the wire feeder12 in the direction of the torch may reduce stresses on the wire and/orwire feeder 12. During operation, the swivel 18 may enable the operatorto move along the horizontal axis 48, 50 relative to the modular weldingsystem 10 without deforming the wire. In some embodiments, the wirefeeder 12 and first housing surface 36 of the swivel 18 may rotate aboutthe horizontal axes 48, 50 relative to the power supply 20. In someembodiments, the swivel 18 may be considered to be a part of the wirefeeder 12 or the power supply 20. As discussed below, coupling the wirefeeder 12 to the power supply 20 may include a separate swivel 18coupled between the wire feeder 12 and the power supply 20. In someembodiments, the wire feeder 12 is rotatably coupled to the power supply20.

A power supply bottom housing 54 may be removably coupled to a thirdhousing surface 56 of the cooler 28 and/or to a fourth housing surface58 of the transportation device 30. The power supply bottom housing 54has a second mating geometry, and both the third and fourth housingsurfaces 56, 58 have a second complementary geometry that couples withthe second mating geometry. The power supply bottom housing 54 may beremovably coupled to the third housing surface 56 and/or the fourthhousing surface 58, thereby limiting movement of the cooler 28 ortransportation device 30 along the coordinate axes 44, 48, 50 relativeto the power supply 20. In some embodiments, the second mating geometryis substantially the same as the first mating geometry, and the secondcomplementary geometry is substantially the same as the firstcomplementary geometry. The similar first and second mating geometriesmay increase the modularity and interchangeability of the modularwelding system.

In some embodiments, the power supply bottom housing 54 and the third orfourth housing surfaces 56, 58 share a second hole pattern 60 (e.g.,bolt holes) to accommodate fasteners. Embodiments in which the secondhole pattern 60 is the first hole pattern 40 may increase the modularityof the modular welding system 10. In some embodiments, the power supplybottom housing 54 may interlock (e.g., nest) with the third or fourthhousing surfaces 56, 58. For example, the third and fourth housingsurfaces 56, 58 may have a recessed portion 62 (e.g., perimeter) and araised portion 64 (e.g., interior), and the power supply bottom housing54 may have one or more legs 66 (e.g., rails along the perimeter) thatextend from the bottom surface of the power supply 20. The recessedportion 62 of the cooler 28 or the transportation device 30 may receivethe one or more legs 66 (e.g., rails), and the bottom surface receivesthe raised portion 64.

The transportation device 30 may removably couple with components of themodular welding system 10, such as the wire feeder 12, the power supply20 and/or the cooler 28. In some embodiments, supports 68 of thetransportation device 30 extend and retract along the X-axis 48 toaccommodate differently sized modular components. A rack 70 of thetransportation device 30 may receive and secure one or more fluidstorage tanks 72 (e.g., cylinders, bottles) for the modular weldingsystem 10. In some embodiments, the storage tanks 72 may supplyshielding gas for a welding operation, fuel for a cutting operation,coolant for the cooler 28, or any combination thereof.

In some embodiments of the modular welding system 10, the housings ofthe modular components (e.g., wire feeder 12, swivel 18, power supply20, cooler 28, transportation device 30) have male top surfaces andfemale bottom surfaces. In other embodiments, the housings of themodular components of the modular welding system 10 may have female topsurfaces and male bottom surfaces, or any combination thereof that mayenable the modular components to interchangeably couple with one anotherin a modular manner. Moreover, the wire feeder 12 may removably couplewith the power supply 20 via a first mating relationship (e.g., flangeand channel, first nesting geometry, first hole pattern), and the cooler28 and/or transportation device may removably couple with the powersupply 20 via a second mating relationship (e.g., e.g., flange andchannel, second nesting geometry, second hole pattern). In someembodiments, the first mating relationship is interchangeable with thesecond mating relationship, thereby facilitating the arrangement of themodular components in various configurations of the modular weldingsystem 10. For example, the cooler 28 may be coupled between the wirefeeder 12 and the power supply 20.

As described above and shown in FIG. 1 , the modular welding system 10may have multiple configurations of the modular components. Some of thecomponents, such as the wire feeder 12 and power supply 20, may havemultiple form factors with varying capacities or options available tothe operator. Table 1 is set forth below to list some of the variousconfigurations of the modular welding system 10. The components of eachof the configurations may be removably coupled to one another as shownin FIG. 1 , or in another arrangement as the mating geometries maypermit.

TABLE 1 Configurations of modular welding components in the modularwelding system 10. Modular Component 12 20 Configuration 14 16 18 22 2426 28 30 1 X X 2 X X 3 X X X 4 X X 5 X X 6 X X X 7 X X 8 X X 9 X X X 10X X 11 X X X 12 X X X X 13 X X X X 14 X X X X X 15 X X X 16 X X X X 17 XX X 18 X X 19 X X X 20 X X X X 21 X X X X 22 X X X X X 23 X X X 24 X X XX 25 X X X 26 X X 27 X X X 28 X X X X 29 X X X X 30 X X X X X 31 X X X32 X X X X 33 X X X 34 X X 35 X X X 36 X X X X 37 X X X X 38 X X X X X39 X X X 40 X X X X 41 X X X 42 X X 43 X X X 44 X X X X 45 X X X X 46 XX X X X 47 X X X 48 X X X X 49 X X X 50 X X 51 X X X 52 X X X X 53 X X XX 54 X X X X X 55 X X X 56 X X X X 57 X X X

FIG. 2 illustrates a top-view of an embodiment of the wire feeder 12(e.g., single-wire wire feeder 14) and the power supply 20 (e.g., secondinverter power supply 24). In some embodiments, the second housingsurface 38 of the power supply 20 has a rim 90 raised along the verticalaxis 44 from an interior 96. When a modular component (e.g., wire feeder12, swivel 18) interfaces with the interior 96 of the second housingsurface 38, the rim 90 (e.g., lip) may block movement of the modularcomponent in one or more horizontal directions 48, 50 relative to thepower supply 20. In some embodiments, the rim 90 that forms a channel 92between the rim 90 and an interior 96 of the second housing surface 96.The rim 90 may substantially lie along a portion of a perimeter 94 ofthe power supply 20, or the rim 90 may lie within the interior 96 of thesecond housing surface 38. In some embodiments, one or more flanges 96of the wire feeder bottom housing 34 may be inserted (e.g., arrow 97)into the channel 92 to removably couple the wire feeder 12 to the secondhousing surface 38 of the power supply 20. A flange 96 of the swivel 18coupled to the feeder 12 may also be inserted into the channel 92. Inother embodiments, the rim 90 and channel 92 are on the wire feederbottom housing 34 and removably receive one or more flanges 96 of thesecond housing surface 38 of the power supply 20.

The wire feeder bottom housing 34 and the second housing surface 38 mayhave mating complementary shapes that facilitate removably coupling themodular components. For example, the flanges 96 of the wire feeder 12may interface with the rim 90 of the power supply 20, and a receivingportion 98 of the second housing surface 38 may receive a front portion100 (e.g., input panel) of the wire feeder 12. The receiving portion 98may be recessed in the second housing surface 38 and configured to seatthe front portion 100. Seating the front portion 100 may stabilize thewire feeder 12. In some embodiments, the second housing surface 38 ofthe power supply 20 removably couples with and positions the wire feeder12 so that one or more faces of the wire feeder 12 are positioned with adesired spacing relative to one or more faces of the power supply 20.For example, the second housing surface 38 may couple with the wirefeeder bottom housing 34 so that the rear face 102 of the wire feeder 12is substantially flush with the rear face 104 of the power supply 20.

FIG. 3 illustrates a perspective view of an embodiment of the wirefeeder bottom housing 34. FIG. 4 illustrates a perspective view of anembodiment of the power supply 20 with various mating features. FIGS. 3and 4 are discussed together to clarify the various mating relationshipsof the modular components of the modular welding system 10. In someembodiments of the wire feeders 12, the wire feeder bottom housing 34may be common between the single-wire wire feeder 14 and the dual-wirewire feeder 16. Thus, a second mating surface 38 of the power supply 20configured to couple with the single-wire wire feeder 14 may also couplewith a the dual-wire wire feeder 16. Additionally, the swivel 18 mayhave a geometry similar to the wire feeder bottom housing 34,facilitating the coupling of the swivel 18 between the wire feeder 12and the power supply 20. Accordingly, the discussion below related tothe wire feeder bottom housing 34 may also pertain to embodiments of theswivel 18.

Embodiments of the wire feeder bottom housing 34 with flanges 96 mayhave a flange thickness 120 that is less than or approximately equal toa channel height 122. In some embodiments, the wire feeder bottomhousing 34 may be coupled to the second housing surface 38 along ahorizontal axis, such as the X-axis 48 from the rear face 104 of thepower supply 20 as shown in FIG. 2 (e.g., arrow 97). In otherembodiments, the one or more flanges 96 may be tabs along the length(e.g., X-axis 48), and the rim 90 may have multiple openings 124. Thetabs 96 may be inserted along the vertical axis 44 to interface with thesecond housing surface 38. The wire feeder 12 may then translate (e.g.,slide) along a horizontal axis 48, 50 to engage the flanges 96 (e.g.,tabs) within the channel 92 of the second housing surface 38.

In some embodiments, the first hole pattern 40 extends through the wirefeeder bottom housing 34 and the second housing surface 38. As may beappreciated, various fasteners 126 (e.g., bolts, screws, clips, and soforth) may extend through the first hole pattern 40 of both housings(e.g., wire feeder bottom housing 34, second housing surface 38) toremovably attach the wire feeder 12 to the power supply 20. Thefasteners 126 may be inserted with or without the use of tools (e.g.,screwdriver, wrench). The first hole pattern 40 may be common to any ofthe modular components, such as the wire feeder bottom housings 34 ofthe single-wire wire feeder 14 and the dual-wire wire feeder 16, thefirst housing surface 36 of the swivel 18, the second housing surface 38of the power supply 20, or any combination thereof.

The power supply 20 may have a lift eye 42 to facilitate transport ofthe power supply 20. The lift eye 42 may extend from the second housingsurface 38 along the vertical axis 44. The lift eye 42 may be utilizedto position modular components (e.g., wire feeder 12, swivel 18) on thesecond housing surface 38. In some embodiments, the wire feeder bottomhousing 34 has one or more recesses 46 (e.g., slots) to receive the lifteye 42 when the wire feeder 12 is positioned on the second housingsurface 38 of the power supply 20. A bolt 128 or other fastener mayextend through the lift eye 42 to secure the wire feeder bottom portion34 to the second housing surface 38 along the vertical axis 44. The lifteye 42 and recesses 46 may facilitate positioning the wire feeder 12relative to the power supply 20 along the horizontal axes 48, 50. Thelift eye 42 may be fixed to the power supply 20 at a certain horizontalposition relative to vertical surfaces, such as a rear surface 104, aright surface 130, a front surface 132, and a left surface 134.Accordingly, aligning the recess 46 with the lift eye 42 may positionthe wire feeder 12 relative to the power supply 20 based at least inpart on the certain position. Accordingly, multiple recesses 46, asshown in FIG. 3 , may enable the wire feeder 12 to be removably coupledto the second housing surface 38 in multiple positions. For example,placing the lift eye 42 through a first recess may align the rearsurfaces 102, 104, and placing the lift eye 42 through a second recessmay offset the rear surfaces 102, 104.

Embodiments of the wire feeder bottom housing 34 and the second housingsurface 38 of the power supply 20 are not limited to the geometries andfeatures described above and shown in FIGS. 3 and 4 . FIGS. 5-7illustrate embodiments of the power supply bottom housing 54, thirdhousing surface 56 of the cooler 28, and fourth housing surface 58 ofthe transportation device 30. The mating geometries and features of theembodiments in FIGS. 5-7 may differ from the embodiments of FIGS. 3 and4 . However it may be appreciated that each modular component of themodular welding system 10 may utilize one or more of the matinggeometries described herein and shown in FIGS. 3-7 . For example, therim 90, channel 92, and one or more flanges 96 described above with thewire feeder bottom housing 34 and the second housing surface 38 of thepower supply 20 may be utilized to removably couple the power supplybottom housing 54 to the cooler 28 and/or to the transportation device30.

FIG. 5 illustrates an assembly view of an embodiment of the modularwelding system 10 in which the modular components have male-femalemating features configured to form the modular welding system 10. Themodular components (e.g., power supply 20, cooler 28, transportationdevice 30) may interlock with one another to restrict relative movementalong the coordinate axes 44, 48, 50. In some embodiments, the powersupply bottom housing 54 has one or more legs 66 (e.g., rails along theside surfaces 130, 134) that extend from a bottom surface 150 of thepower supply 20. When the power supply bottom housing 54 removablycouples to the third housing surface 56, the one or more legs 66 extendtowards the recessed portion 62 of the cooler 28, and the raised portionof the third housing surface 56 extends towards the bottom surface 150.The arrangement of the recessed portion 62 and raised portion 64 of thelower modular component (e.g., transportation device 30, cooler 28)affect how the upper modular component (e.g., power supply 20, cooler28) is restrained along the coordinate axes 44, 48, 50 when removablycoupled to the lower modular component. As shown in FIG. 5 , the legs 66extending along the side surfaces 130, 134 (along the X-axis 48) of thepower supply 20 into the recessed portion 62 of the cooler 28 may limitthe movement of the power supply 20 along the Z-axis 50 relative to thecooler 28.

One or more posts 152 (e.g., dowels) may extend through one or both ofthe power supply 20 and the cooler 28 to position and retain the powersupply 20 along the X-axis 48. The posts 152 may extend into the lowermodular component, into the upper modular component, or any combinationthereof. In some embodiments, the one or more posts 152 are a separatecomponent inserted into recess 154 prior to assembly (e.g., stacking) ofthe modular welding system 10. Additionally, one or more fasteners 126may be inserted through the second hole set 60 shared with the powersupply 20, the cooler 28, and/or the transportation device 30. In FIG. 5, the second hole set 60 is accessible through one or more assemblyports 156.

In some embodiments, one or more snaps 158 of a modular component (e.g.,transportation device 30) may interface with engagement portions 160 onsurfaces 104, 130, 132, 134 of another modular component (e.g., powersupply bottom housing 54, cooler 28). In some embodiments, the snaps 158may include ball detents that are spring loaded to interface with theengagement portions 160. The snaps 158 may be biased toward theengagement portions 160 to limit the movement of the engaged modularcomponent (e.g., power supply 20) relative to engaging modular component(e.g., cooler 28). In some embodiments, the snaps 158 are utilized withinterlocking (e.g., nesting) modular components as shown in FIG. 5 .

The mating features shown in FIG. 5 may passively couple the modularcomponents of the modular welding system 10 to one another. That is, themale features (e.g., legs 66, extended portion 64, posts 152, snaps 158)and female features (e.g., bottom surface 150, recessed portion 62,recesses 154, engagement portions 160) may passively engage each otherand restrict relative movement of modular components without manualengagement of a mating feature by the operator. For example, theoperator may place the cooler 28 on the transportation device 30 alongthe vertical axis 44 with the posts 152 aligned with the recesses 154 toremovably couple the cooler 28 to the transportation device 30. Passivecoupling the modular components may reduce the time to assemble ordisassemble the modular welding system 10. Additionally, the operatormay assemble or disassemble some embodiments of the modular weldingsystem 10 without utilizing tools (e.g., screwdriver, wrench).

As shown in FIG. 6 , the power supply bottom housing 54 and/or thecooler 28 may removably couple with the fourth housing surface 58 of thetransportation device 30 with hooking features 170. In some embodiments,the hooking features 170 of the power supply bottom housing 54 engagelinks 172 of the cooler 28 or the transportation device 30. The links172 may be arranged within recesses 174 of the third and fourth housingsurfaces 56, 58, or on the exterior housings of the cooler 28 ortransportation device 30. Some embodiments of the hooking features 170may passively engage the links 172 for tool-free attachment of the powersupply 20 to the cooler 28 and/or transportation device 30.

FIG. 7 illustrates an embodiment of the power supply bottom housing 54and/or the cooler 28 that may removably couple with the fourth housingsurface 58 of the transportation device 30 with mounting hardware 180.The mounting hardware 180 may include, but is not limited to latches,straps, brackets, and so forth. The mounting hardware 180 may bearranged about the side surfaces 104, 130, 132, 134 of the modularcomponent. In some embodiments, the mounting hardware 180 has a latchbase 182 proximate to a bottom edge 184 of the upper modular component(e.g., power supply 20), and a catch 186 proximate to a top edge 188 ofthe lower modular component (e.g., cooler 28). The upper modularcomponent is positioned to interface with the lower modular componentand aligned so that the latch base 182 substantially aligns with thecatch 186. Then the operator engages a latch 190 to the catch 186,removably coupling the upper modular component to the lower modularcomponent. In some embodiments, engaging the latch 190 pulls the modularcomponents together. The mounting hardware 180 is positioned at commonlocations of the modular components, thereby enabling the latch bases182 and latches 190 of power supply 20 to engage with the catches 186 ofeither the cooler 28 or the transportation device 30.

The embodiments illustrated in FIGS. 3-7 disclose various matinggeometries and mating features of the modular components of the modularwelding system 10. Each of the modular components (e.g., wire feeder 12,swivel 18, power supply 20, cooler 28, transportation device 30) may beremovably coupled to another modular component based at least in part ona shared mating geometry or mating feature. In some embodiments, thewire feeder 12 may couple directly with the cooler 28 and/ortransportation device 30 separately from a power supply 20. Moreover,various form factors of the power supply 20 may removably couple withthe wire feeder 12 and the cooler 28. Thus, in some embodiments variousform factors of the components (e.g., wire feeder 12, power supply 20)are fully interchangeable with another component of the same type.Additionally, one or more of the mating features described above (e.g.,lift eye 42, posts 152, legs 66) may couple and position the modularcomponents so that one or more faces (e.g., front face 132) of the powersupply 20, wire feeder 12, and cooler 28 are substantially flush withone another. Some embodiments of the modular welding system 10 may havea first mating relationship between some modular components (e.g., wirefeeder 12, swivel 18, and second housing surface 38 of the power supply20) and a second mating relationship between other modular components(e.g., power supply bottom housing 54, cooler 28, transportation device30). Where the first mating relationship (e.g., flange and channel,nesting geometry, hole pattern, mounting hardware, or any combinationthereof) is compatible with the second mating relationship, eachcomponent of the modular welding system 10 may be fully interchangeablewith one another.

Moreover, FIGS. 2-4 illustrate various mating interfaces between thewire feeder 12 and the power supply 20, and FIGS. 5-7 illustrate variousmating interfaces between the power supply 20 and the cooler 28 ortransportation device 30. Some embodiments of the power supply 20 maycouple with the cooler 28 or transportation device 30 via one or more ofthe mating relationships (e.g., flange 96 and channel 92, nestinggeometries, hole pattern 40) shown in FIGS. 2-4 . In a similar manner,some embodiments of the power supply 20 may couple with the wire feeder12 or swivel 18 via one or more of the mating relationships (e.g.,nesting geometry, posts 152, hole pattern 60, snaps 158, hook feature170, mounting hardware 180) shown in FIGS. 5-7 . Furthermore, thepresent disclosure is not limited to the male-female relationshipsillustrated in FIGS. 1-7 . Specifically, presently contemplatedembodiments include the opposite mating geometries and any combinationsof the male-female relationships described above that facilitate themodular arrangement of the modular components into a modular weldingsystem 10. For example, some embodiments of the power supply bottomhousing 54 may have a raised portion 64 and a recessed portion 62 thatmates (e.g., nests) with legs 66 and a top surface of the cooler 28,which is substantially the opposite of the mating relationship shown inFIG. 5 .

FIG. 8 is a flowchart of a method 200 of assembling the modular weldingsystem described above. Being a modular welding system, the modularcomponents may be arranged in a variety of configurations. The method200 provides an example of how an operator may utilize the modularwelding system and switch modular components. However, the modularwelding system may be assembled and reassembled by other methods asdescribed above. The operator selects (block 202) the desired modularcomponents to be assembled into the modular welding system. For example,the operator may select the single-wire wire feeder for a typicalwelding application utilizing a single type of electrode, and thedual-wire wire feeder for a relatively complex welding application thatspecifies different types of welds. In some embodiments, the operatormay then couple (block 204) the first wire feeder to a swivel. The firstwire feeder and swivel may be removably coupled to one another via oneor more of the mating geometries and mating features described above.The first wire feeder is then coupled (block 206) by the mating geometryto the selected first power supply via the swivel. Similarly, the swivelmay be removably coupled to the first power supply via one or more ofthe mating geometries and mating features described above, such as thelift eye. In some embodiments, the mating geometries coupling the swivelto the first wire feeder and to the first power supply may besubstantially complementary.

After the first power supply is coupled with the first wire feeder, thefirst power supply may be coupled (block 208) to the cooler. The firstpower supply and the cooler may be removably coupled to one another viaone or more of the mating geometries and mating features describedabove. The first power supply is then coupled (block 210) to theselected transportation device via the cooler. Similarly, the cooler maybe removably coupled to the transportation device via one or more of themating geometries and mating features described above. In someembodiments, the mating geometries coupling the cooler to the firstpower supply and to the transportation device may be substantiallycomplementary. The method 200 above starts with the first wire feederthat may be positioned at the top of the modular welding system. Otherembodiments of the method 200 may start with coupling the cooler to thetransportation device at the bottom of the modular welding system.

The operator may perform (block 212) one or more welding applicationsutilizing the assembled modular welding system. After use of the modularwelding system, the operator may desire to remove some modularcomponents or exchange some modular components with others. The operatormay remove (block 214) the first wire feeder and the swivel from thefirst power supply. The operator may also remove (block 216) the firstpower supply and remove (block 218) the cooler. The operator may couple(block 220) a second power supply to the selected transportation devicewith or without a cooler. The operator may then couple (block 222) theswivel to the second power supply, and couple (block 224) the secondwire feeder to the second power supply via the swivel. Based at least inpart on the modular components selected, the modular welding systemafter block 210 may have different capabilities and operating parametersthan the modular welding system after block 224.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A wire feeder, comprising: a wire driveconfigured to supply a welding wire to a welding tool; and a wire feederhousing disposed about the wire drive, the wire feeder housingcomprising a mating geometry configured to mate with a complementarygeometry of a modular component of a welding system, wherein the matinggeometry comprises: a first flange extending from a first edge of a baseof the wire feeder housing, and a second flange extending from a secondedge of the base of the wire feeder housing, and an aperture in the baseof the wire feeder housing, the aperture being configured for alignmentwith a lifting or alignment mechanism of a welding power supply.
 2. Thewire feeder of claim 1, wherein the mating geometry is part of a bottomof the wire feeder housing.
 3. The wire feeder of claim 2, furthercomprising a door at a top of the wire feeder, opposite the bottom ofthe wire feeder.
 4. The wire feeder of claim 1, wherein the wire feederhousing is configured to enclose a wire spool carrying the welding wire.5. The wire feeder of claim 1, wherein the first flange extends outwardfrom the first edge of the base in a first direction, and the secondflange extends outward from the second edge of the base in a seconddirection, the second edge being opposite the first edge, the seconddirection being opposite the first direction, and the aperture beingpositioned between the first edge and the second edge.
 6. The wirefeeder of claim 1, wherein the modular component comprises one or moreof a swivel, a welding power supply, a torch cooler, or a transportationdevice.
 7. The wire feeder of claim 1, wherein the aperture comprises anelliptical aperture, and the major axis of the elliptical aperture isparallel with the first or second edge.
 8. The wire feeder of claim 1,further comprising a plurality of apertures, the plurality of aperturescomprising the aperture.
 9. The wire feeder of claim 8, wherein theaperture comprises a first elliptical aperture having a first majoraxis, the plurality of apertures further comprising a second ellipticalaperture having a second major axis that is parallel to the first majoraxis.
 10. The wire feeder of claim 9, wherein the first major axis andsecond major axis are aligned.
 11. A welding wire feeder, comprising: awire drive configured to supply a welding wire to a welding tool; and awire feeder housing disposed about the wire drive, the wire feederhousing comprising a top portion and a bottom portion opposite the topportion, the bottom portion comprising a mating geometry configured tomate with a complementary geometry of a modular component of a weldingsystem, and wherein the mating geometry comprises: a first flangeextending from a first edge of a base of the wire feeder housing, and asecond flange extending from a second edge of the base of the wirefeeder housing, and an aperture in the base of the wire feeder housing,the aperture being configured for alignment with a lifting or alignmentmechanism of a welding power supply.
 12. The wire feeder of claim 11,further comprising a door at a top of the wire feeder, opposite thebottom of the wire feeder.
 13. The wire feeder of claim 12, wherein thedoor is configured to open to provide access to a wire spool within aninterior of the wire feeder.
 14. The wire feeder of claim 11, whereinthe mating geometry further comprises a third flange extending from thefirst edge of the base of the wire feeder housing, and a fourth flangeextending from the second edge of the base of the wire feeder housing.15. The wire feeder of claim 11, wherein the first flange extendsoutward from the first edge of the base in a first direction, and thesecond flange extends outward from the second edge of the base in asecond direction, the second edge being opposite the first edge, thesecond direction being opposite the first direction, and the aperturebeing positioned between the first edge and the second edge.
 16. Thewire feeder of claim 11, wherein the modular component comprises one ormore of a swivel, a welding power supply, a torch cooler, or atransportation device.
 17. The wire feeder of claim 11, wherein theaperture comprises an elliptical aperture, and the major axis of theelliptical aperture is parallel with the first and second edge.
 18. Thewire feeder of claim 11, further comprising a plurality of apertures,the plurality of apertures comprising the aperture.
 19. The wire feederof claim 18, wherein the aperture comprises a first elliptical aperturehaving a first major axis, the plurality of apertures further comprisinga second elliptical aperture having a second major axis that is parallelto the first major axis.
 20. The wire feeder of claim 19, wherein thefirst major axis and second major axis are aligned.